This standard outlines the specifications for copper alloy horizontal plunger float valves used in water supply installations. It details the valve dimensions, materials, manufacturing quality, mechanical durability, hydraulic testing, and marking requirements for both low and high-pressure valves. These guidelines are vital for manufacturers, suppliers, and engineers to guarantee dependable valve performance aligned with Indian water fitting standards.
Overview
This standard outlines the specifications for copper alloy horizontal plunger float valves used in water supply installations. It details the valve dimensions, materials, manufacturing quality, mechanical durability, hydraulic testing, and marking requirements for both low and high-pressure valves. These guidelines are vital for manufacturers, suppliers, and engineers to guarantee dependable valve performance aligned with Indian water fitting standards.
Audience
Contents
Structure
This section defines the scope and specifies critical dimensions and tolerances for copper alloy horizontal plunger float valves used in water supply systems. It covers sizes ranging from 15 mm to 50 mm for both low and high pressure applications, detailing dimensions for pistons, levers, and valve bodies. Included are tables presenting piston diameters, lengths, external thread sizes, and lever arm measurements to ensure proper fit and function.
Lists the Indian Standards referred to within this code, including those applicable to thread specifications, materials, and testing methods. It emphasizes the importance of adhering to IS 2:1960 for rounding off numerical data and highlights key tables that provide dimensional details for various valve components.
Describes classification criteria distinguishing low pressure and high pressure float valves, including dimensional differences and marking conventions (LP and HP). It references tables specifying body and inlet pipe dimensions for each category and outlines lever arm length requirements for load testing.
Details the nominal size dimensions for valve bodies, including bore sizes, outer diameters, flange measurements, and thicknesses of various parts. It also specifies minimum metal thicknesses required for outlet noses and piston sockets across different sizes.
Specifies the materials used for different valve components such as bodies, levers, back nuts, and inlet pipes. It includes references to the relevant IS grades for cast brass, leaded-tin bronze, and brass rods, ensuring corrosion resistance and mechanical suitability.
Outlines manufacturing practices including machining accuracy, surface finish quality, and assembly alignment. It emphasizes the mechanical properties required of lever materials to prevent deformation while allowing necessary adjustments.
Provides detailed dimensional requirements and construction guidelines for levers and valve bodies. This includes minimum metal thicknesses, screw thread specifications, and provisions for split pins and fastening components.
Describes the hydraulic pressure testing and mechanical strength evaluations required for float valves. It details test pressures, load applications on levers, acceptance criteria, and instructions for rounding off test results in compliance with IS 2:1960.
Specifies marking details including manufacturer identification, valve size, class, and manufacturing date or batch number. It outlines the use of the BIS Standard Mark and general packaging practices aimed at protecting the valve during transport and storage.
Provides instructions on installation dimensions, lever specifications, piston fitting, and minimum metal thicknesses. It also covers maintenance considerations to ensure long-lasting and reliable valve operation.
Enumerates the Indian Standards cited within this code, explaining their relevance to material quality, testing methods, dimensional accuracy, and rounding rules.
Lists the committee responsible for preparing the standard, including representatives from government bodies, research organizations, manufacturers, and public health institutions.
Frequently Asked
The standard mandates specific materials for various parts of copper alloy float valves: valve bodies and associated components (excluding levers and back nuts) are made from cast brass (Grade LCB 2) or leaded-tin bronze (Grade LTB 2) according to IS 292, IS 1264, and IS 318. Lever rods are manufactured from half-hard brass rods complying with IS 319, IS 8364, IS 320, and IS 6912. Back nuts and inlet pipe nuts utilize brass or leaded-tin bronze of specified grades, while inlet pipes conform to IS 407 brass specifications. These materials ensure suitable corrosion resistance and mechanical durability for water supply applications.
The standard differentiates float valves based on operating pressure: high pressure valves are intended for mains pressures equal to or exceeding 0.175 MPa and are marked 'HP', while low pressure valves cater to pressures below 0.175 MPa and are marked 'LP'. Each category has specific dimensional requirements for valve bodies and inlet pipes detailed in separate tables. Furthermore, high pressure valves must remain closed under a test pressure of 1.05 MPa with the float half immersed, whereas low pressure valves are tested at 0.35 MPa, ensuring suitable performance under designated pressure conditions.
Levers undergo mechanical strength testing by applying a gradually increasing load at specified leverage points, as defined in the standard's Table 7. The lever must be rigidly mounted during the test and must not exhibit any permanent deformation or set after the load application. The design ensures that when the washer contacts the seat, the lever's short arm is nearly vertical to effectively transfer the load. This test confirms that the lever can endure operational stresses without compromising valve performance.
Dimensional specifications vary based on nominal valve size and pressure classification. For low pressure valves, dimensions follow Table 2(a), whereas high pressure valves conform to Table 2(b). For 15 mm valves featuring vertical inlet shanks, Tables 3(a) and 3(b) provide respective dimensions. Key parameters include bore diameter of seating, outer diameter, seating length, flange diameter, bore of inlet, and minimum thickness from the root of the flange. Notably, high pressure valves have reduced bore sizes to optimize material use without sacrificing functionality.
Hydraulic testing involves assembling the valve with the float submerged halfway and subjecting it to specified test pressures—1.05 MPa for high pressure valves and 0.35 MPa for low pressure valves. The valve must remain sealed under these pressures without any leakage. Additionally, a strength test applies 1.5 MPa internal pressure for at least two minutes, ensuring no leakage or sweating occurs. These procedures validate the valve's ability to maintain integrity and function under operational pressures.
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